Instruction Manual. Alfa Laval Agitator - ALT / ALTB ESE03504-EN Original manual

Transcription

1 Instruction Manual Alfa Laval Agitator - ALT / ALTB ESE03504-EN Original manual

2

3 Table of contents The information herein is correct at the time of issue but may be subject to change without prior notice. EC Declaration of Conformity Safety Important information Warning signs Intended use Safety precautions Installation Unpacking/delivery Installation Pre-use check Recycling information Operation Operation/Control Troubleshooting Cleaning - recommendations Temperature limits Maintenance General Maintenance Replacement of drive unit with bearing frame Replacement of drive unit Replacement of drive unit (Motor and shaft unit) Dismantling and mounting shaft (with bearing frame except BC60) Replacement of bearings, type B0, B5, B5/30, B35, B35/40, B45, B45/50, B55, B55/ Replacement of bearings, type BC60DH Replacement of bearing, type BC60D Replacement of bearings type BC Replacement of shaft seal, type D Replacement of shaft seal, type DC Replacement of shaft seal, type S Replacement of shaft seal, type S Replacement of shaft seal, type R or G Replacement of shaft seal, type V Replacement of wear bushing in intermediate bearing support Replacement of wear bushing in bottom support Technical Data Technical data Mounting angle for top mounting agitator type ALT Mounting angle for top mounting agitator type ALTB Connecting flush Seal type D Connecting flush Seal type DC Tightening torques for bolt connections Shaft alignment Spider coupling Bottom support alignment Bottom support positioning

4 Table of contents The information herein is correct at the time of issue but may be subject to change without prior notice 6..Storage Part lists, part drawings and service kits Agitator Main Components, Drive end Agitator Main Components, Wet end Bearing frame, B0, B5, B5/30, B35, B35/40, B45, B45/50, B55, B55/ Bearing frame BC60/35, BC60D/30, BC60DH/ Shaft seal, type S Shaft seal, type S Shaft seal, type D Shaft seal, type DC Shaft seal, type R Shaft seal, type G Shaft seal, type V Intermediate support Bottom support, type Bottom support, type Bottom support, type Tools Appendix Drive unit instructions... 4

5 EC Declaration of Conformity The Designated Company Alfa Laval Kolding A/S Company Name Albuen 3, DK-6000 Kolding, Denmark Address Phone No. hereby declare that Agitator - EnSaFoil / EnSaFerm Designation Serial no(s) GX = GC, GR or GP BXX/XX = B0, B5, B5/30, B35, B35/40, B45, B45/50, B55, B55/60 ALT(B)-ME-(GX)-BC60D(H)/30(L)F-SX-SH-(n)(PXXXXDYY)(-PXXXXDYLY)(-LXXXXY)(-MSXX)(-BSXX) SX = S, S3 ALT(B)-ME-(GX)-BC60/35(L)F-SX-SH-(n)(PXXXXDYY)(-PXXXXDYLY)(-LXXXXY)(-MSXX)(-BSXX) SH = S500-S5000 ALT(B)-ME-(GX)-BXX/XX(L)F-SX-SH-(n)(PXXXXDYY)(-PXXXXDYLY)(-LXXXXY)(-MSXX)(-BSXX) PXXXX E5, E50, E75, E00, E5, E50, E300 ALT(B)-ME-(GX)-BC60D(H)/30(L)F-D(C)-SH-(n)(PXXXXDYY)(-PXXXXDYLY)(-LXXXXY)(-MSXX)(-BSXX) E350, E400, E450, E500, E550, E600, E650 ALT(B)-ME-(GX)-BC60/35(L)F-D(C)-SH-(n)(PXXXXDYY)(-PXXXXDYLY)(-LXXXXY)(-MSXX)(-BSXX) E700, E750, E800, E900, E000, E00 ALT(B)-ME-(GX)-BXX/XX(L)F-D(C)-SH-(n)(PXXXXDYY)(-PXXXXDYLY)(-LXXXXY)(-MSXX)(-BSXX) E300, E500, E700, E900 ALT(B)-ME-(GX)-BC60D(H)/30(L)F-R-SH-(n)(PXXXXDYY)(-PXXXXDYLY)(-LXXXXY)(-MSXX)(-BSXX) F450, F500, F550, F600, F650, F700, F750, ALT(B)-ME-(GX)-BC60/35(L)F-R-SH-(n)(PXXXXDYY)(-PXXXXDYLY)(-LXXXXY)(-MSXX)(-BSXX) F800, F900, F000, F00, F300, F500 ALT(B)-ME-(GX)-BXX/XX(L)F-R-SH-(n)(PXXXXDYY)(-PXXXXDYLY)(-LXXXXY)(-MSXX)(-BSXX) F700, F900 ALT(B)-ME-(GX)-BC60D(H)/30(L)F-G-SH-(n)(PXXXXDYY)(-PXXXXDYLY)(-LXXXXY)(-MSXX)(-BSXX) LXXXX = L600, L800, L900, L00, L300, ALT(B)-ME-(GX)-BC60/35(L)F-G-SH-(n)(PXXXXDYY)(-PXXXXDYLY)(-LXXXXY)(-MSXX)(-BSXX) L500, L700 ALT(B)-ME-(GX)-BXX/XX(L)F-G-SH-(n)(PXXXXDYY)(-PXXXXDYLY)(-LXXXXY)(-MSXX)(-BSXX) DY = D, D3 ALT(B)-ME-(GX)-ZZ(L)F-SX-SH-(n)(PXXXXDYY)(-PXXXXDYLY)(-LXXXXY)(-MSXX)(-BSXX) Y = P, G ALT(B)-ME-(GX)-ZZ(L)F-D(C)-SH-(n)(PXXXXDYY)(-PXXXXDYLY)(-LXXXXY)(-MSXX)(-BSXX) BSXX BS3P, BS3G ALT(B)-ME-(GX)-ZZ(L)F-R-SH-(n)(PXXXXDYY)(-PXXXXDYLY)(-LXXXXY)(-MSXX)(-BSXX) MSXX = MSP, MSG ALT(B)-ME-(GX)-ZZ(L)F-G-SH-(n)(PXXXXDYY)(-PXXXXDYLY)(-LXXXXY)(-MSXX)(-BSXX) ZZ = 0, 5, 30, 35, 40, 45, 50, 55, 60, 65, ALT-ME-ZZF-V-SH-PXXXXDYY 70, 75, 80, 90 Type Type variation is in conformity with the following directives: Machinery Directive 006/4/EC++ Regulation (EC) 935/004 The person authorised to compile the technical file is the signer of this document. Global Product Quality Manager Pumps, Valves, Fittings and Tank Equipment Title Lars Kruse Andersen Name Kolding Place Date Signature (This Declaration of Conformity replaces Declaration of Conformity dated ) 5

6 Safety Unsafe practices and other important information are emphasised in this manual. Warnings are emphasised by means of special signs. Always read the manual before using the Agitator! Illustrations are only to illustrate the problem and is NOT a drawing of the current Agitator!. Important information WARNING Indicates that special procedures must be followed to avoid serious personal injury. CAUTION Indicates that special procedures must be followed to avoid damage to the agitator! NOTE Indicates important information to simplify or clarify procedures.. Warning signs General warning: Dangerous electrical voltage:.3 Intended use - The Alfa Laval Agitator is only for mixing/stirring of liquids in a tank. - The Agitator is only for mounting positions as specified on the nameplate by the first group of letters of the type designation. ALT(B)- is for top mounting, ALS- is for side mounting and ALB- is for bottom mounting. The exact mounting angle is specified on the Name Plate and must be followed. Definitions on mounting angles can be seen in section 6. Mounting angle for top mounting agitator type ALT. - The different duties and operation data like pressure, speed and media temperature, which the Agitator is designed for, can be found in the Alfa Laval quotation agreement ) and may not be exceeded by all means. - If the Agitator is installed in pressurized tanks local regulations and legislations must be met. ) The Alfa Laval quotation agreement has been exchanged during the quote process between a technical purchaser and Alfa Laval. If you are not in hold of the Alfa Laval quotation agreement, please get through to your local Alfa Laval contact, inform the Agitator serial number and article number which is stated on the Name Plate and you will obtain the Alfa Laval quotation agreement. 6

7 Safety All warnings in the manual are summarised on this page. Pay special attention to the instructions below so that severe personal injury and/or damage to the Agitator are avoided..4 Safety precautions Installation: Always read the technical data thoroughly (see chapter 6 Technical Data). Always follow installation instructions thoroughly (see chapter 3 Installation). Never expose the Agitator to undue vibrations or shocks. Never start Agitator in the wrong rotation direction. Ensure that the tank media is not corrosive to the Agitator. Only install the Agitator in environments within temperature limit: -0 C and +40 C. Only install the Agitator in altitudes less than 000 m above sea level.! Never touch the moving parts while the Agitator is connected to the power supply. Operation: Always read the technical data thoroughly (see chapter 6 Technical Data). Always read supplier instructions thoroughly (see chapter 8 Appendix). Never start Agitator in the wrong rotation direction. Always rinse well with clean water after cleaning. Beware of temperature limitations. Beware of Agitator in operation can produce sound levels in excess of 85dB(A). Never operate continuously within 0% of critical oscillation speed (see chapter 6 Technical Data).! Never touch the moving parts while the Agitator is connected to the power supply. Maintenance: Always read the technical data thoroughly (see chapter 6 Technical Data). Always follow the maintenance instruction thoroughly (see chapter 5 Maintenance). Always follow the maintenance instruction from drive unit supplier (see chapter 8 Appendix). Always study the parts list and assembly drawing carefully (see chapter 7 Part lists, part drawings and service kits).! Never touch the moving parts while the Agitator is connected to the power supply. Always disconnect the power supply while servicing the Agitator. Ensure correct rotation direction of impeller before startup and after any maintains there might have impact on the direction. Transportation: Always transport the Agitator in original packaging. Always support the shaft adequately, to protect shaft and bearings. Never expose the Agitator to undue vibrations or shocks. Control for oil leakage on gears with vent screw. 7

8 3 Installation The instructions manual is part of the delivery. Study the instructions carefully. 3. Unpacking/delivery Always use lifting equipment when handling the Agitator (see step 3). CAUTION Alfa Laval cannot be held responsible for incorrect unpacking. Step Inspect the delivery for visible transportation damages - all issues to be reported to carrier. Step Check the delivery for:. Complete Agitator. Nameplate designations 3. Delivery note 4. Separate instruction manuals from suppliers (see chapter 8 Appendix) Step 3 Lifting instructions: Always use the correct lifting equipment (see Agitator weight on name plate). Locate Centre of gravity before moving the Agitator

9 3 Installation The instructions manual is part of the delivery. Study the instructions carefully. TD WARNING Do NOT use eye bolts on gear motor to lift the Agitator. They are only for gear motor removal. TD605-0 WARNING Do NOT use eye bolts on shroud (if any) to lift the Agitator. They are only for shroud removal

10 3 Installation The instructions manual is part of the delivery. Study the instructions carefully. CAUTION Alfa Laval recommends NOT to use shaft as lifting point but long shafts must be supported adequately during lifting to protect shaft, bearings and seals arrangements. Gear motor / motor may be used for lifting the assembled agitator. NOTE If possible, lift the Agitator in horizontal position, and in two points. Step 4 During transportation. Always support the shaft adequately, to protect shaft and bearings.. Never expose the Agitator to undue vibrations or shocks. 3. Control for oil leakage on gears with vent screw. 0

11 3 Installation Study the instructions carefully and pay special attention to the warnings! Always check the Agitator before operation - see section 3.3 Pre-use check. The Agitator is for permanent fastening. Make sure that the motor correspond to the environment. 3. Installation Always read the technical data thoroughly (see chapter 6 Technical Data). Only install this Agitator in mounting angle according to the name plate (see chapter 6 Technical Data). Always use lifting equipment when handling the Agitator (see Step ). Always have safety elements removed by authorized personnel. Never cover or remove the nameplate. Never connect to power supply during installation or service. Always have the Agitator connected to power supply by authorized personnel. NOTE Alfa Laval highly recommend to install motor protection guard to protect the motor from overloading. NeverinstallanoneAlfaLavalshroudontheagitatoras it can lead to overheat and a breakdown of the motor. Alfa Laval highly recommends to use shaft retainer tool for installation of Agitator within a weight less than 500 kilogram and a shaft diameter between Ø30 and Ø60 (see section 7.6 Tools). Welding flange - Flat Shaped Welding Flange (FSWF): CAUTION Only authorized personnel to weld in flanges. Alfa Laval cannot be held responsible for incorrect installation. TD Step Dismantle the FSWF if fitted onto the Agitator. TD

12 3 Installation Study the instructions carefully and pay special attention to the warnings! Always check the Agitator before operation - see section 3.3 Pre-use check. The Agitator is for permanent fastening. Make sure that the motor correspond to the environment. Step Ensure that the tank, where the welding flange are to be welded in, can handle the forces applied by the agitator: Torque Mv, Bending torque Mb and Side thrust Fs. TD The values are depending on the Agitator configuration. The following information is required to calculate the forces: Mb P: Power of the motor in [kw] n: Speed of Agitator shaft [RPM] S: Shaft length according to Agitator type designation -Sxxxxin [mm] D: Largest impeller diameter according to Agitator designation -Pxxx- in [mm] Fs Mb Mv Fs The values can be calculated as follows: Type ALT / ALTB: Mv [Nm] = 3873 x P / n Fs [N] = 4.5 x Mv x 000 / D Type ALT: Mb [Nm] = Fs x S / 000 Type ALTB: Mb [Nm] = Fs x S / 5333 Step 3 During the design phase of the tank, ensure sufficiently rigidity of the tank. Ensure that the max. bending angle (A), at loads from Step does not exceed according to below scheme A RPM: <00 >00 A (max bending angle at applied loads): Mb Fs Mb Fs TD605-3

13 3 Installation Study the instructions carefully and pay special attention to the warnings! Always check the Agitator before operation - see section 3.3 Pre-use check. The Agitator is for permanent fastening. Make sure that the motor correspond to the environment. Guidelines for cutting hole in tank for Flat Shaped Welding Flange (FSWF) CAUTION Alfa Laval recommend that all other welding tasks on the tank are finished before cutting the hole for the flange. Chamfer inner and outer hole edge 45. TD

14 3 Installation Study the instructions carefully and pay special attention to the warnings! Always check the Agitator before operation - see section 3.3 Pre-use check. The Agitator is for permanent fastening. Make sure that the motor correspond to the environment. Welding procedure, flange (FSWF) without nose: Step Always allow flange to cool to ambient temperature after each section has been welded Position the flange correctly A D B TD TD C Step Spot weld from outside. A A D B Adjust alignment! TD D TD605-0 B C C Step 3 Weld the following sections first from outside then from inside, and cool with air between each section. 3 A D TD B 4 C Step 4 Ensure that the surface flatness tolerance equals 0,5 after welding. Grind and polish the welding flange. Use a solid straight ruler and a feeler gauge to determine the flatness

15 3 Installation Study the instructions carefully and pay special attention to the warnings! Always check the Agitator before operation - see section 3.3 Pre-use check. The Agitator is for permanent fastening. Make sure that the motor correspond to the environment. Welding procedure, flange (FSWF) with nose: NOTE Alfa Laval recommend a welding tool with, if possible, build in cooling by flowing water, to be made and fixed to the FSWF to ensure shape and form of the FSWF during welding and installation. In general Alfa Laval recommend to weld the welding flange onto a bended rim of the tank bottom plate this is to secure adequate flexibility at high loads, e.g. when the tank is filled. If a bended rim is impossible to obtain due to a high plate thickness, Alfa Laval recommend to weld the welding flange onto a cone shaped plate section. If not following the above recommendations there will be a risk that the flange can deform, especially at high tank fillings, which can cause a leakage between the welding flange and the agitator mounting flange. Step Position the flange correctly. Always allow flange to cool to ambient temperature after each section has been welded. Step Spot weld from outside. A Adjust alignment! D TD605-5 B TD605-4 C Step 3 Spot weld from inside TD

16 3 Installation Study the instructions carefully and pay special attention to the warnings! Always check the Agitator before operation - see section 3.3 Pre-use check. The Agitator is for permanent fastening. Make sure that the motor correspond to the environment. Step 4 Weld the following sections first from inside then from outside and cool to ambient temperature after each section has been welded Step Step Step 3 A A 8 A H E H E H E 3 4 D TD605-7 B D TD605-8 B D TD605-9 B 7 6 G F G F G F C 5 C Cool with air! Cool with air! Cool with air! C Step 5 Remove the welding tool. Ensure that the surface flatness tolerance equals ±0.mm. Grind and polish the welding flange. 6

17 3 Installation Study the instructions carefully and pay special attention to the warnings! Always check the Agitator before operation - see section 3.3 Pre-use check. The Agitator is for permanent fastening. Make sure that the motor correspond to the environment. Welding procedure for divided shaft with thread connection: NOTE Only relevant for divided shafts prepared for welding. Step Ensure that shaft ends are screwed completely together. Step Spot weld and cool with air. Step 3 All-weld shaft connections with one welding seam at a time, cool with air and continue with one welding until welding is according to illustration. Use welding procedures which introduce as less tension and bending to the shaft as possible. Step 4 If shaft sleeve is used weld as described in step 3. Step 5 Align the shaft, using heat and or bending forces according to specifications in section 6.7 Shaft alignment. 7

18 3 Installation Study the instructions carefully and pay special attention to the warnings! Always check the Agitator before operation - see section 3.3 Pre-use check. The Agitator is for permanent fastening. Make sure that the motor correspond to the environment. Mounting Agitator: CAUTION Always ensure that mounting is carried out according to description shown in section 6. Mounting angle for top mounting agitator type ALT and 6.3 Mounting angle for top mounting agitator type ALTB. Always refer to tightening torques in section 6.6 Tightening torques for bolt connections when tightening bolts. Step Place impeller device(s) in the tank. Ensure that tank and Agitator surfaces are clean. Ensure that drain (I) is pointing downwards. For gears with vent screw, ensure the vent is pointing upwards and the rubber plug (III) is removed (see section 8. Drive unit instructions). III I ) Standard vent plug ) Transport securing device Step Mount the Agitator onto the tank. NOTE Alfa Laval recommends using shaft retainer tool during mounting and dismantling (see section 7.6 Tools). Step 3 (Only for ALTB machines with Intermediate steady bearing) - Mount the intermediate steady bearing onto the shaft. - Ensure before welding that the intermediate steady bearing is perpendicular to the mounting flange. - Position wear bushings according to shaft diameter. TD

19 3 Installation Study the instructions carefully and pay special attention to the warnings! Always check the Agitator before operation - see section 3.3 Pre-use check. The Agitator is for permanent fastening. Make sure that the motor correspond to the environment. Step 4 Mount impeller device(s) onto shaft. 3 x TD Hub diameter [mm] a - dimension [mm] Ø30, Ø40,8 Ø55, Ø80, Ø0,8 3 x a TD a All-weld propeller to shaft with one welding seam at a time, cool with air and continue with one welding until welding is according to illustration. Use welding procedures which introduce as less heat, tension and bending to the shaft as possible. TD TD x 4 x TD TD TD TD Step 5 Ensure the impeller device orientation is correct according to the direction of the desired flow. The direction is determined by the letter "D" or "U" in the last part of the agitator type description. E.g. -P400D3P has the letter "D" which means the flow direction is away from the drive unit. -P400U3P has the letter "U" which means the flow direction is towards the drive unit. 9

20 3 Installation Study the instructions carefully and pay special attention to the warnings! Always check the Agitator before operation - see section 3.3 Pre-use check. The Agitator is for permanent fastening. Make sure that the motor correspond to the environment. Step 6 Ensure the impeller is positioned, keeping minimum radial distance to the tank. Further installation requirements regarding the position can be found in 6. Mounting angle for top mounting agitator type ALT and 6.3 Mounting angle for top mounting agitator type ALTB to ensure optimum performance. S S > 5 Clearance > S/5xsin(V) Clearence TD V NOTE In special cases clearance can be reduce to 0mm+actual deflection, please advice with Alfa Laval. Step 7 (Only when shaft is divided) Assembleallshaftpartsasshownonthefigure. Step 8 Align the shaft, using heat and or bending forces according to specifications and instructions in section 6.7 Shaft alignment. Step 9 (Only for ALTB machines) - Adjust legs according to tank bottom shape and position bottom steady bearing having center line of the bottom steady bearing perpendicular to the mounting flange and according to tolerances and dimensions given in Alfa Laval quotation agreement which is showninsection.3intended use and section 6. Technical data. X NOTE Alfa Laval recommends using a small plate for reinforcement below each leg before welding into tank X >X X 0

21 3 Installation Study the instructions carefully and pay special attention to the warnings! Always check the Agitator before operation - see section 3.3 Pre-use check. The Agitator is for permanent fastening. Make sure that the motor correspond to the environment. WARNING Do NOT connect the power supply until installation is completed. CAUTION Follow instructions in section 8. Drive unit instructions Ensure that the rotation direction is according to nameplate. Always perform pre-use check before operation (see section 3.3 Pre-use check). NOTE On closed tanks, Alfa Laval recommends installing a manhole circuit breaker, cutting power supply if hatch is open.

22 3 Installation Study the instructions carefully and pay special attention to the warnings! Always check the Agitator before operation. The Agitator is only designed to operate according to data given in section.3 Intended use, 6. Mounting angle for top mounting agitator type ALT and 6.3 Mounting angle for top mounting agitator type ALTB Check the rotation direction before operation. 3.3 Pre-use check Never install the Agitator in environments which deviate from those given in section.3 Intended use and 6. Technical data. Always ensure that all alignment specifications given in section 6.7 Shaft alignment are followed. Always make sure that the motor corresponds to the environment. Step Go through section.4 Safety precautions. Step Check the fastenings. Step 3 Check o-ring and impeller are correctly fitted. Step 4 Check impellers CANNOT collide with tank vessel at any point during a full rotation. Clearance > S/5*sin(V) NOTE In special cases clearance can be reduced to 0mm+actual deflection, please advise with Alfa Laval. S S > 5 Clearence TD V Step 5 Seal Type D Ensure the sealing surfaces are not stuck together, by slowly turning shaft by hand. Ensure that the seal never runs dry. Ensure flush connections are installed in such way that air pockets are avoided. TD TD

23 3 Installation Study the instructions carefully and pay special attention to the warnings! Always check the Agitator before operation. The Agitator is only designed to operate according to data given in section.3 Intended use, 6. Mounting angle for top mounting agitator type ALT and 6.3 Mounting angle for top mounting agitator type ALTB Check the rotation direction before operation. Step 6 Seal Type DC Ensure the sealing surfaces are not stuck together, by slowly turning shaft by hand. Ensure that the seal never runs dry. Ensure flush connections are installed in such way that air pockets are avoided. Ensure that the distance pieces () on the seal are mounted as shown on illustration. OUT TD IN Step 7 Ensure that drain (I) is pointing downwards. For gears with vent screw, ensure the vent is pointing upwards and the rubber plug (III) is removed (see section 8. Drive unit instructions and mounting instructions in Step on page 8. III I Step 8 (Only for agitators with bearing frame) Ensure that the PreVent valve is refitted in the bearing frame. TD

24 3 Installation Study the instructions carefully and pay special attention to the warnings! Always check the Agitator before operation. The Agitator is only designed to operate according to data given in section.3 Intended use, 6. Mounting angle for top mounting agitator type ALT and 6.3 Mounting angle for top mounting agitator type ALTB Check the rotation direction before operation. Step 9 Ensure that the rotation direction is according to nameplate, before starting the Agitator. TD TD Step 0 If frequency converter drive is used, it must be ensured NOT to operate continuously within +/-0% of critical oscillation speed (see section.3 Intended use and 6. Technical data). Step Alfa Laval recommend a soft starter or a frequency converter for the Agitator to reduce the load on tank and Agitator. For operation instructions from suppliers see 8 Appendix. The ramp up and ramp down time should be about -5 seconds. 3.4 Recycling information Unpacking - Packing material consists of wood, plastics, cardboard boxes and in some cases metal straps. - Wood and cardboard boxes can be re-used, recycled or used for energy recovery. - Plastics should be recycled or burnt at a licensed waste incineration plant. - Metal straps should be sent for material recycling. Maintenance - During maintenance, oil and wear parts in the machine are replaced. - All metal parts should be sent for material recycling. - Worn out or defective electronic parts should be sent to a licensed handler for material recycling. - Oil and all non-metal wear parts must be disposed of in accordance with local regulations. Scrapping - At the end of use, the equipment must be recycled according to the relevant, local regulations. Besides the equipment itself, any hazardous residues from the process liquid must be considered and dealt with in a proper manner. When in doubt, or in the absence of local regulations, please contact your local Alfa Laval sales company. 4

25 4 Operation Study the instructions carefully and pay special attention to warnings! Always check the Agitator before operation (see section 3.3 Pre-use check). Alfa Laval recommend a soft starter or a frequency converter for the Agitator to reduce the load on tank and Agitator. For operation instructions from suppliers (see chapter 8 Appendix). 4. Operation/Control If deviation from normal operation and intended use shown in section.3 Intended use, immediately switch off the Agitator and find the cause of failure (see section 4. Troubleshooting). The Agitator is designed to max 5 starts per hour. The Agitator is normally constructed for use with the lower impeller adequately submerged in the liquid. However, the Agitator can be dimensioned for use while emptying the tank completely (see section.3 Intended use). Inspect the Agitator regularly Supplier instruction Drive unit Motor x - Clean surfaces - to avoid overheating x Gear x - Clean vent screw (if any) x - Check for oil leakage x Flange Clean drain Inspect / Clean / Lubricate Weekly Monthly Half-yearly x Sealing Shaft seal - Radial seal: R x - Gab seal: G - V-ring seal: V x Mechanical seal -NOTflushed:S,S3 x -Flushed: DC,D x Bearing frame Clean PreVent screw x Check spider clearance x Check gaskets x Lubricate radial seals x Guidance Shaft rotation - radial movement < 5mm - Bushing: BS3 x - Bushing: MS x Impeller device Sticky media - Clean impeller device x Abrasive media - Check blade thickness* x Check fastening of pointed set screws x * If any suspicion of reduction in blade thickness, contact Alfa Laval and inform serial no stated on the name plate. 5

26 4 Operation Study the instructions carefully and pay special attention to warnings! Always check the Agitator before operation (see section 3.3 Pre-use check). Alfa Laval recommend a soft starter or a frequency converter for the Agitator to reduce the load on tank and Agitator. For operation instructions from suppliers (see chapter 8 Appendix). 4. Troubleshooting Problem Not starting Drive unit Cause/result Remedy - Defect Dismantle drive unit, check for correct rotation. Replace drive unit - Fault at power supply Check power supply connection Check voltage and frequency correspond with name plate Check frequency converter adjustment correspond to name plate Agitator - Obstructed Check Agitator can rotate freely without stricking anything Bearing frame Ensure that retainer bolt has been removed Vibrations Impeller device - Damaged Contact Alfa Laval - Unbalanced impeller Clean impeller device - Damage to shaft seal Replace sealing Shaft - Damaged Contact Alfa Laval Other - Deviation from normal operation Operation circumstances must equal to those it was designed for ) - Increased / decreased temperature Unusual noise Bearing frame - Bearing gap Replace bearings and all gaskets in bearing frame immediately - Wear or damaged bearings Replace bearings and all gaskets in bearing frame Drive unit - Defect Replace drive unit - Bearing gap Renovate or change the drive unit immediately - Increased / decreased power Switch of power supply Sealing Other - No grease Replace drive unit - Wear sealing Replace sealing - Seal are not flushed ) Replace sealing and ensure that the seal never run dry ) - Seal surfaces stick together Separate surfaces carefully and clean them - ensure that seals are sufficient cleaned before still stand - Deviation from normal operation Operation circumstances must be equal to those it was designed for ) - Circuit overload Operation circumstances must be equal to those it was designed for ) Leakage Gear - Oil leakage Renovate or change the gear immediately Sealing - CIP fluid or other Replace sealing Continuously breakdown Drive unit - Defect Replace motor - Too high frequency Regulate frequency down Other - Deviation from normal operation Operation circumstances must be equal to those it was designed for ) Performance Drive unit - Wrong frequency Check frequency connection Agitator - Reverse direction Inspect the Agitator carefully Other - Deviation from normal operation Operation circumstances must be equal to those it was designed for ) ) See section.3 Intended use. ) Type S and S3 are designed for dry running. 6

27 4 Operation Study the instructions carefully and pay special attention to warnings! Always check the Agitator before operation (see section 3.3 Pre-use check). Alfa Laval recommend a soft starter or a frequency converter for the Agitator to reduce the load on tank and Agitator. For operation instructions from suppliers (see chapter 8 Appendix). 4.3 Cleaning - recommendations Ensure the drain in flange is not clogged up, by cleaning drain regularly. Ensure that all surfaces in contact with product are totally clean in order not to contaminate the product. Pay special attention to: - Impeller device surfaces - Surfaces between impeller devices and shaft - Surfaces around sealing - Surfaces around weldings CAUTION Mechanical seals are designed for cleaning in place (CIP) and sterilising in place (SIP). CIP = Cleaning In Place. SIP = Sterilising In Place. Always rinse well with clean water after cleaning. 4.4 Temperature limits The highest allowable ambient temperature is 40ºC. For applications without bearing frame (not ATEX): The highest allowable continuous temperature of the SHAFT that goes into the gear motor is 05 C. Shorter periods with higher application temperatures, eg. 0-0 minutes during a sterilization phase or the like, can be allowed and accepted without changing the oil service interval and without reducing the lifetime of the gear motor. If longer periods with exceeded application temperatures are required, the actual temperature of the oil in the gear motor must be measured. The highest allowable oil temperature is 40 C and the oil service interval, which at 70 C is about hours, will be reduced by 50% for each 5K the oil temperature is increased above the 70 C. For applications with bearing frame (not ATEX): The highest allowable continuous temperature of the SHAFT that goes into the bearing frame is 05 C. Shorter periods with higher application temperatures, eg. 0-0 minutes during a sterilization phase or the like, can be allowed and accepted without changing the service interval and without reducing the lifetime of the bearings. If longer periods with exceeded application temperatures are required, the actual temperature of the bearings must be measured. The highest allowable bearing temperature, without changing the service interval, is 0 C. For applications with bottom support: The bottom support is designed for a continuous operating temperature up to C with O-rings material EPDM and 50 C with O-rings material FPM. The temperature for the O-rings material EPDM may go as high as 50 C for a short period of time, but the increased temperature reduces the flexibility of the O-rings and ages them over time. In these cases it is recommended, due to sanitary reasons, regularly to inspect the O-rings for eventually leakage by disassembling the bushing from the shaft. 7

28 5 Maintenance For maintenance instructions from suppliers, see chapter 8 Appendix. Always ensure that mounting is according to chapter 6 Technical Data. Ensure totally clean surfaces during mounting - also remove remaining loctite residue on threads. Always refer to tightening torques in section 6.6 Tightening torques for bolt connections. 5. General Maintenance Maintenance of the Agitator should only be performed by authorized personnel. For maintenance instructions from suppliers, see chapter 8 Appendix. Ensure totally clean surfaces during maintenance. If possible, always dismount the Agitator from tank before dismantling it. Otherwise it is recommended to purchase a shaft retainer tool (see section 7.6 Tools). For lifting instruction, please refer to chapter 3 Installation. Always read the technical data thoroughly (see chapter 6 Technical Data). Always ensure that the mounting is according to agitator described in section.3 Intended use and chapter 6. Technical data. Always refer to tightening torques in section 6.6 Tightening torques for bolt connections. Always disconnect the power supply when servicing the Agitator. Always use proper tools. Always replace sealing elements before reassembling. WARNING Follow the dismantling and assembly instructions to the letter. After maintenance, section 3.3 Pre-use check must be read thoroughly before operation. NOTE All scrap must be stored/disposed of in accordance with current rules/directives. Use original Alfa Laval spare parts. 500 hour or yearly 000 hour or yearly Replace every: 3000 hour or yearly 3000 hour or every 3rd year 6000 hour or every 3rd year Sealing Shaft seal - Radial seal: R x - Gab seal: G x - V-ring seal: V x Mechanical seal -NOT flushed: S, S3 x -Flushed, rpm < 500: DC, D x -Flushed, rpm > 500: DC, D x Bearing frame Spider type coupling (if any) Static seals Radial seals x Bearings, rpm < 700 Bearings, rpm > 700 x Guidance Bushing: BS3 Bushing: MS x Bushing: MS Replace if temperature > 00 C x x x x 8

29 5 Maintenance For maintenance instructions from suppliers, see chapter 8 Appendix. Always ensure that mounting is according to chapter 6 Technical Data. Ensure totally clean surfaces during mounting - also remove remaining loctite residue on threads. Always refer to tightening torques in section 6.6 Tightening torques for bolt connections. 5. Replacement of drive unit with bearing frame Step Remove shroud, if any. TD Step Loosen cap nuts. CAUTION If dismantling motor from gear: - Follow supplier instructions. - Ensure that the gear oil is contained. - A cog wheel may be mounted onto the motor shaft. TD Step 3 Release the gear motor from the Agitator. CAUTION There is a spider type coupling mounted onto the gear motor shaft. Step 4 Lift up the drive unit and pull it away. TD Step 5. Loosen coupling screws.. Pull the coupling of the gear motor shaft. TD

30 5 Maintenance For maintenance instructions from suppliers, see chapter 8 Appendix. Always ensure that mounting is according to chapter 6 Technical Data. Ensure totally clean surfaces during mounting - also remove remaining loctite residue on threads. Always refer to tightening torques in section 6.6 Tightening torques for bolt connections. Step 6 Replace drive unit. Mount coupling. XX NOTE Coupling part can be heated to 80-0 C for easier mounting onto gear motor shaft. CAUTION Ensure that the axial position of the coupling is according to illustration. The value XX is to be found in section 6.8 Spider coupling. TD Step 7 Replace spider if necessary. Use Loctite 43 before fastening screws. Always refer to tightening torques in section 6. Technical data when tightening bolts. Step 8 Mount drive unit reverse as dismantling. 30

31 5 Maintenance For maintenance instructions from suppliers, see chapter 8 Appendix. Always ensure that mounting is according to chapter 6 Technical Data. Ensure totally clean surfaces during mounting - also remove remaining loctite residue on threads. Always refer to tightening torques in section 6.6 Tightening torques for bolt connections. 5.3 Replacement of drive unit Step Remove shroud, if any. TD Step. Dismantle Agitator from welding flange.. Lift up Agitator. TD Step 3 Support shaft using shaft retainer tool. NOTE Alfa Laval highly recommends to use shaft retainer tool for installation of Agitator within a weight less than 500 kilograms and a shaft diameter between Ø30 and Ø60 (see section 7.6 Tools). TD Step 4 Before dismantling drive unit, please see instructions in 5.0 Replacement of shaft seal, type D to 5.3 Replacement of shaft seal, type S3, depending on seal type. Step 5 Loosen cap nuts. CAUTION If dismantling motor from gear: - Follow supplier instructions - Ensure that the gear oil is contained - A cog wheel may be mounted onto the motor shaft.td

32 5 Maintenance For maintenance instructions from suppliers, see chapter 8 Appendix. Always ensure that mounting is according to chapter 6 Technical Data. Ensure totally clean surfaces during mounting - also remove remaining loctite residue on threads. Always refer to tightening torques in section 6.6 Tightening torques for bolt connections. Step 6 Release the gear motor from the Agitator. Refer to supplier instructions CAUTION There is a Nord-lock washer mounted on the gear fastening the shaft. The washer consists of two parts attached to each other with some silicone as shown on the picture. It is important that the two parts are positioned as shown. TD Step 7 Lift up the drive unit and pull it away. TD Step 8 Replacement drive unit. Step 9 Use Loctite 43 before fastening screws. Always refer to tightening torques in section 6.6 Tightening torques for bolt connections. Step 0 Mount drive unit reverse as dismantling. 3

33 5 Maintenance For maintenance instructions from suppliers, see chapter 8 Appendix. Always ensure that mounting is according to chapter 6 Technical Data. Ensure totally clean surfaces during mounting - also remove remaining loctite residue on threads. Always refer to tightening torques in section 6.6 Tightening torques for bolt connections. 5.4 Replacement of drive unit (Motor and shaft unit) Step Remove shroud, if any. TD Step Loosen cap nuts. TD Step 3 Release the motor from the Agitator. CAUTION Motor and shaft are one complete unit. Step 4 Lift up the drive unit and pull it away. Step 5 Replace drive unit. Step 6 Use Loctite 43 before fastening screws. Always refer to tightening torques in section 6.6 Tightening torques for bolt connections. Step 7 Mount drive unit reverse as dismantling. 33

34 5 Maintenance For maintenance instructions from suppliers, see chapter 8 Appendix. Always ensure that mounting is according to chapter 6 Technical Data. Ensure totally clean surfaces during mounting - also remove remaining loctite residue on threads. Always refer to tightening torques in section 6.6 Tightening torques for bolt connections. 5.5 Dismantling and mounting shaft (with bearing frame except BC60) Step. Dismantle Agitator from welding flange.. Lift up Agitator. TD Step Support shaft using shaft retainer tool. NOTE Alfa Laval highly recommends to use shaft retainer tool for installation of Agitator within a weight less than 500 kilograms and a shaft diameter between Ø30 and Ø60 (see section 7.6 Tools). TD Step 3. Dismantle drive unit as described in section 5. Replacement of drive unit with bearing frame.. Remove PreVent valve. TD Step 4 Looking through the PreVent valve hole, rotate shaft until shaft locking hole aligns. TD

35 5 Maintenance For maintenance instructions from suppliers, see chapter 8 Appendix. Always ensure that mounting is according to chapter 6 Technical Data. Ensure totally clean surfaces during mounting - also remove remaining loctite residue on threads. Always refer to tightening torques in section 6.6 Tightening torques for bolt connections. Step 5. Mount retainer bolt tool for shaft locking.. Remove centre bolt. NOTE Extra retainer bolt tool can be acquired if needed (see section 7.6 Tools) or Spare Part Manual. TD Step 6 Remove spider and coupling part Step 7 Dismantle shaft by mounting extractor bolt tool. Keep turning extractor bolt until shaft is forced from the bearing frame. NOTE Extra extractor bolt tool can be acquired if needed (see section 7.6 Tools or Spare Part Manual). TD Step 8 Mount shaft reverse as dismantling CAUTION Ensure that oil trap ring, if any, is refitted correct during mounting. 35

36 5 Maintenance For maintenance instructions from suppliers, see chapter 8 Appendix. Always ensure that mounting is according to chapter 6 Technical Data. Ensure totally clean surfaces during mounting - also remove remaining loctite residue on threads. Always refer to tightening torques in section 6.6 Tightening torques for bolt connections. 5.6 Replacement of bearings, type B0, B5, B5/30, B35, B35/40, B45, B45/50, B55, B55/ TD NOTE Positions referred to in following instructions can be seen in the above illustration. Step. Dismantle shaft as described in section 5.5 Dismantling and mounting shaft (with bearing frame except BC60).. Remove retainer bolt in step 5 in section 5.5 Dismantling and mounting shaft (with bearing frame except BC60). Step. Remove cap nuts ().. Remove lantern or mounting flange if no lantern is used from bearing frame. TD Step 3. Push cover () into bearing frame.. Remove o-ring (). TD Step 4 Remove cover () including radial seal (3) and spring (3). TD

37 5 Maintenance For maintenance instructions from suppliers, see chapter 8 Appendix. Always ensure that mounting is according to chapter 6 Technical Data. Ensure totally clean surfaces during mounting - also remove remaining loctite residue on threads. Always refer to tightening torques in section 6.6 Tightening torques for bolt connections. Step 5 Remove outer circlip (0) carefully. Use suited pliers. TD Step 6. Pull out drive shaft (4) including bearings (8, 9).. Remove o-ring (7) TD Step 7. Remove inner circlip (4) carefully. Use suited pliers.. Remover bearings (8, 9) TD Step 8. Replace bearings (8, 9) and o-rings (6, 7,, 5).. Assembly of bearing frame is reverse as dismantling. CAUTION Only apply force to inner bearing rings when mounting bearings on drive shaft. Only apply force to outer bearing rings when mounting drive shaft with bearings into bearing frame. 37

38 5 Maintenance For maintenance instructions from suppliers, see chapter 8 Appendix. Always ensure that mounting is according to chapter 6 Technical Data. Ensure totally clean surfaces during mounting - also remove remaining loctite residue on threads. Always refer to tightening torques in section 6.6 Tightening torques for bolt connections. 5.7 Replacement of bearings, type BC60DH TD NOTE Positions referred to in following instructions can be seen in the above illustration. Step Dismantle shaft as described in section 5.5 Dismantling and mounting shaft (with bearing frame except BC60). Step. Remove cap nuts ().. Remove lantern or mounting flange if no lantern is used from bearing frame. TD Step 3 Remove radial seal (3). NOTE Alfa Laval recommends replacing the radial seal. 3 TD Step 4 Remove outer circlip (0) carefully. Use suited pliers. TD Step 5. Pull out drive shaft (4) including bearings (8, 9).. Remove O-rings, (7), (). 38

39 5 Maintenance For maintenance instructions from suppliers, see chapter 8 Appendix. Always ensure that mounting is according to chapter 6 Technical Data. Ensure totally clean surfaces during mounting - also remove remaining loctite residue on threads. Always refer to tightening torques in section 6.6 Tightening torques for bolt connections. Step 6. Remove spring ring (3).. Remove inner circlip (4) carefully. Use suited pliers. 3. Remove bearings (8, 9) TD Step 7. Replace bearings (8, 9) and o-rings (6, 7, ).. Assembly of bearing frame is reverse as dismantling. CAUTION Only apply force to inner bearing rings when mounting bearings on drive shaft. Only apply force to outer bearing rings when mounting drive shaft with bearings into bearing frame. 39

40 5 Maintenance For maintenance instructions from suppliers, see chapter 8 Appendix. Always ensure that mounting is according to chapter 6 Technical Data. Ensure totally clean surfaces during mounting - also remove remaining loctite residue on threads. Always refer to tightening torques in section 6.6 Tightening torques for bolt connections. 5.8 Replacement of bearing, type BC60D TD NOTE Positions referred to in following instructions can be seen in the above illustration. Step Dismantle shaft as described in section 5.5 Dismantling and mounting shaft (with bearing frame except BC60). Step. Remove cap nuts ().. Remove lantern or mounting flange if no lantern is used from bearing frame TD Step 3 Remove radial seal (3). NOTE Alfa Laval recommends replacing the radial seal. 3 TD Step 4 Remove outer circlip (0) carefully. Use suited pliers. TD

41 5 Maintenance For maintenance instructions from suppliers, see chapter 8 Appendix. Always ensure that mounting is according to chapter 6 Technical Data. Ensure totally clean surfaces during mounting - also remove remaining loctite residue on threads. Always refer to tightening torques in section 6.6 Tightening torques for bolt connections. Step 5. Pull out drive shaft (4) including bearings (8a, 9).. Pull out circlip () or let it stay in bearing frame. NOTE Outer bearing ring (8b) should stay in bearing frame 9 4 8a 8b TD Step 6. Remove upper circlip (3) carefully. Use suited pliers. Push out, using applicable tool, the outer bearing ring (8b). 3. Remove o-rings (7, ). 3 8b TD Step 7. Remove inner circlip (4) carefully. Use suited pliers.. Remove bearings (8a, 9) 9 8a TD Step 8. Replace bearings (8a, 8b), (9) and o-rings (6, 7, ).. Assembly of bearing frame is reverse as dismantling. CAUTION Only apply force to inner bearing rings when mounting bearings on drive shaft. Only apply force to outer bearing rings when mounting drive shaft with bearings into bearing frame 4

42 5 Maintenance For maintenance instructions from suppliers, see chapter 8 Appendix. Always ensure that mounting is according to chapter 6 Technical Data. Ensure totally clean surfaces during mounting - also remove remaining loctite residue on threads. Always refer to tightening torques in section 6.6 Tightening torques for bolt connections. 5.9 Replacement of bearings type BC TD NOTE Positions referred to in following instructions can be seen in the above illustration. Step Dismantle drive unit as described in section 5. Replacement of drive unit with bearing frame. Step. Remove cap nuts ().. Remove lantern or mounting flange if no lantern is used from bearing frame. TD Step 3 Remove radial seal (3). NOTE Alfa Laval recommends replacing the radial seal. 3 TD Step 4 Remove outer circlip (0) carefully. Use suited pliers. TD

43 5 Maintenance For maintenance instructions from suppliers, see chapter 8 Appendix. Always ensure that mounting is according to chapter 6 Technical Data. Ensure totally clean surfaces during mounting - also remove remaining loctite residue on threads. Always refer to tightening torques in section 6.6 Tightening torques for bolt connections. Step 5. Pull out shaft (4) including bearings (8, 9).. Remove o-rings (7, ) TD Step 6. Secure shaft (4), without causing surface damage to it.. Remove coupling () by turning it the opposite direction indicated by arrow on nameplate TD Step 7. Remove bearing (8).. Remove inner circlip (4) carefully. Use suited pliers. 3. Remove bearing (9) TD Step 8. Replace bearings (8, 9) and o-rings (6, 7, ).. Assembly of bearing frame is reverse as dismantling. CAUTION Only apply force to inner bearing rings when mounting bearings on drive shaft. 43

44 5 Maintenance For maintenance instructions from suppliers, see chapter 8 Appendix. Always ensure that mounting is according to chapter 6 Technical Data. Ensure totally clean surfaces during mounting - also remove remaining loctite residue on threads. Always refer to tightening torques in section 6.6 Tightening torques for bolt connections. 5.0 Replacement of shaft seal, type D 0 3 TD NOTE To replace seals easier, use detergent. Ensure subsequent to seal replacement, that all seal faces are totally clean, using alcohol. Positions referred to in following instructions can be seen in the above illustration. NOTE If possible, always dismantle the Agitator from the tank before dismounting any parts. Step. Dismantle Agitator from welding flange.. Lift up Agitator TD Step Support shaft using shaft retainer tool. NOTE Alfa Laval highly recommends to use shaft retainer tool for installation of Agitator within a weight less than 500 kilograms and a shaft diameter between Ø30 and Ø60 (see section 7.6 Tools). 44